Method of making a snack food

ABSTRACT

An improved snack food product in the form of resilient, molded, self-sustaining bodies preferably made from a heated mixture comprising a dairy product (cheese, yogurt or pudding), gelatin, fat and water. The product bodies are small and bite sized, having a mass to surface area ratio of from about 0.05-5 g/cm 2 , which facilitates molding thereof. Preferred food products are prepared by first creating a heated flowable mixture of including cheese, gelatin, fat and water, and depositing small quantities of the mixture into molding depressions formed in powdered starch; after hardening, the resultant products are separated from the starch and packaged.

RELATED APPLICATION

This is a divisional application of Ser. No. 09/450,967 filed Nov. 30,1999, now U.S. Pat. No. 6,235,321.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is concerned with an improved molded snack foodproduct and method for preparing such product. More particularly, theinvention pertains to resilient, self-sustaining, chewable food bodiesincluding non-gelatin protein (at least a part of which is dairyproduct-derived protein), gelatin, water and fat; in preferred forms,the products contain a substantial fraction of a dairy product such ascheese, yogurt or pudding. The method of the invention involves starchmolding of heated flowable food mixtures by first forming appropriatelyconfigured depressions in a starch layer, depositing the food mixture inthe depressions and allowing hardening thereof, followed by separatingthe finished food products from the starch.

2. Description of the Prior Art

The prior art relating to the manufacture of dairy products such ascheeses and yogurts is immense. Through the years, a huge variety ofcheeses and other products have been prepared with a multitude ofdifferent ingredients. Commonly, hard cheeses such as cheddars areproduced in large block form and are later subdivided as slices orshreds. Similarly, soft cheeses in the nature of mozzarellas areproduced as blocks or cubes and are then cut or shredded for use.

The growth in snack food consumption over the past few decades has beensubstantial. Many consumers prefer the ease and convenience associatedwith snack foods such as pretzels, chips, granola bars and the like.However, these snack foods are often perceived as lacking in nutritionand bear the onus of non-natural or “artificial” foods. Certain types ofcheeses and particularly mozzarellas have been packaged in tubularcontainers for ready consumption. While these products have achieved acertain measure of success, they are not particularly attractive toyoung children.

U.S. Pat. No. 5,846,579 to Haggerman et al. describes hard cheeses wheregelatin is added during the cheese-making process. Thus, gelatin may beadded to the cheese milk before rennet addition or after whey-off. Thegelatin is described as adding resilience and taste to the final cheeseproduct. The '579 patent is not concerned with production ofattractively shaped, small snack-type products.

U.S. Pat. Nos. 5,679,395, 3,615,690 and 5,330,773 also describe the useof gelatin as an additive in cream cheese, molded meat and cheesecomposites, and as an additive during cheese making. Here again, thesereferences do not deal with the production of small, bite sized snackproducts.

There is accordingly a need in the art for an improved food productwhich includes a substantial fraction of cheese or other dairy product,and which can be molded to virtually any shape (e.g., sports orrecreational items) to yield resilient snacks having desirable mouthfeel and taste properties.

SUMMARY OF THE INVENTION

The present invention overcomes the problems outlined above, andprovides improved food products in the form of resilient,self-sustaining bodies having non-gelatin protein (at least a part ofwhich is derived from dairy product(s)), gelatin, fat and water. Theproducts are relatively small and bite sized, and have a mass to surfacearea ratio of from about 0.05-5 g/cm². Preferably, the molded bodieshave a pH of from about 4.4-6.2, and a water activity of from about0.7-1, whereby the bodies have substantial shelf lives. The gelatinfraction gives the bodies a desired resilience and mouth feel.

Preferably, the molded food bodies of the invention include asubstantial proportion of one or more dairy products such as cheese,yogurt and pudding therein. These base materials provide non-gelatinprotein and also give the final products desirable taste and texturequalities. In this connection, such base materials are supplemented withgelatin and other ingredients such as whey, milk solids, flavorants andcolorants.

In preparative procedures, a flowable mixture is created by heating andmixing the desired starting ingredients, followed by high shearprocessing. Good results have been obtained through the use of anauger-type lay down mixer with direct steam injection into the mixtureduring blending to achieve a mixture temperature of from about 150-190°F. Thereupon, the heated mixture is passed through a high shear mixer orhomogenizer until essential homogeneity is achieved.

In order to mold the bite sized products, a starch molding technique isfollowed. Specifically, a layer of powdered starch is prepared, whereinthe starch is at a temperature of from about 50-100° F. and has areduced moisture content of about 5-8% by weight. The starch layer isthen imprinted with an impression device to form a series of shapeddepressions therein. These depressions are filled with the heated foodmixture, and the latter is allowed to harden therein at a temperature offrom about 30-90° F. The hardened bodies are then separated from thestarch, allowed to equilibrate, and are packaged.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view illustrating the first step in the productmolding process wherein preconditioned starch is placed within a tray;

FIG. 2 is a schematic vertical sectional view illustrating the starchtray after starch skimming to present an essentially flat top surface onthe starch layer;

FIG. 3 is a schematic vertical sectional view depicting placement of aproduct mold above a filled starch tray;

FIG. 4 is a schematic vertical sectional view illustrating molding ofdepressions in the starch layer using the product mold;

FIG. 5 is a schematic vertical sectional representation depicting formeddepressions in the starch layer;

FIG. 6 is a schematic top view illustrating a series of the depressionsformed in the starch layer;

FIG. 7 is a schematic vertical sectional view showing filling of thedepressions with a heated flowable food mixture;

FIG. 8 is a schematic vertical sectional view depicting separation ofthe molded food products from the starch; and

FIG. 9 is a perspective view of a formed food product in accordance withthe invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred process in accordance with the invention is illustratedschematically in the drawing. The process is in some ways similar tostarch molding processes long practiced in the candy and confectionaryindustries. In the first step (FIG. 1), particulate starch 10 isdeposited into a tray or similar holder 12. It is important that thestarch (which can be derived from any common source) be preconditionedto reduce the moisture content thereof In particular, starch as-receivedcommonly has a moisture content of 10-11% by weight, but it has beenfound that this moisture content should be reduced to a level of fromabout 5-8% by weight for use in the invention. Moreover, the starchshould be at essentially room temperature or slightly warmer, preferablyabout 70-100° F. If the particulate starch is not preconditioned to arelatively low moisture content, the starch tends to agglomerate on thesurface of the final product, and is difficult to remove.

FIG. 2 illustrates the starch 10 within tray 12 after filling andskimming of the starch. This presents an upper surface 14 for the starchlayer as best seen in FIG. 2. It is to be understood that the starchlayer is not pressed into the tray 12, but rather starch is merelydumped into the tray 12 and skimmed off using a knife or the like toprovide the flat upper surface 14. The density of the starch in the trayis preferably from about 0.5-0.7 g/cm².

The next step (FIG. 3) involves forming a series of depressions oropenings in the starch 10 through the upper surface 14. A variety ofequipment can be used for this purpose, but in the example of thedrawing, a plate 16 having a series of depending cylindrical projections18 is positioned above the tray 12. The plate 16 is then pressed intothe starch 10 as shown (FIG. 4) through the upper surface 14. Thiscreates a series of open-top depressions 20 in the starch 10 (FIG. 5)which are complemental with the projections 18. This can better be seenin FIG. 6 which shows that the depressions 20 are in a spaced array.

The depressions 20 are next filled with a flowable food mixture 22 untilthe upper surface of the latter is essentially coincident with starchsurface 14. In the illustrated embodiment, a manifold 24 having a seriesof depending outlet pipes 26 is located above the depressions 20, andthe flowable mixture 22 is directed through the respective pipes 26 forfilling of the depressions. Generally, this flowable mixture has atemperature of from about 150-190° F. during the filling step. Themixture 22 is then allowed to harden within the individual depressions20 to form the self-sustaining bodies 28 of the invention. Suchhardening can be carried out at room temperature or, if desired, in arefrigerated area. In the case of room temperature hardening, a periodof from about 45 minutes to 4 hours is normally sufficient. At the endof the hardening step, the bodies 28 typically have a moisture contentof from about 30-60% by weight and a temperature of from about 40-90° F.The products of the invention have a mass to surface area ratio in therange of from about 0.05-5 g/cm². It has been found that bodies havinggreater than a 5 g/cm² ratio are difficult to mold owing to the factthat the starch tends to tenaciously cling to the surfaces of the bodiesbecause, during hardening, substantial moisture migrates from the bodiesinto the surrounding starch.

The formed bodies 28 are then separated from the starch 10. This can beaccomplished by a variety of techniques. FIG. 8 illustrates one suchmethod wherein the entire contents of the tray 12 are dumped onto asieve apparatus 30 allowing the bulk of the starch 10 to fall into alower collector 32. Thereafter, residual starch is removed from thebodies 28 by directing a positive pressure air stream over the bodieswith appropriate collection of such residual starch. An advantage of theinvention is that the starch so collected from the process can bereused. This involves heating the starch as required to again reduce itsmoisture content to the desired level, which also controls the pathogensin the starch.

The makeup and handling of the flowable food mixture 22 is an importantaspect of the invention. In general, the mixture is made up ofnon-gelatin protein, gelatin, water and fat, wherein the non-gelatinprotein of the mixture comprises a quantity of dairy product-derivedprotein (i.e., protein from dairy products such as cheese, whey andother milk products). In preferred forms, the mixture includes asubstantial proportion of a dairy ingredient selected from the groupconsisting of cheese, yogurt, pudding and mixtures thereof, typicallyfrom about 10-80% by weight, and more preferably from about 15-50% byweight. In the case of cheeses, cream cheese, American, Cheddar, Colby,Monterey Jack, Swiss, mozzarella and mixtures thereof are preferred. Theoverall flowing mixture 22 also typically includes other ingredientssuch as whey powder, non-fat dry milk (NFDM) powder, lactic acids,preservatives and colors.

In order to prepare the flowable mixture, the ingredients are mixedtogether and heated. In one preferred method, such heating isaccomplished by direct steam injection. After such heating, the mixtureis subjected to high shear processing to render the mixture essentiallyhomogenous. The steam injection is carried out until the flowablemixture has the desired temperature of from about 150-190° F. High shearprocessing can be carried out in a high shear mixer (e.g., a Votator) orin a homogenizer. The goal of this processing is to minimize the size ofthe gelatin particles so that these are essentially invisible to the eyein the final product 28.

The following table sets forth broad and preferred ranges for importantingredients and properties of the flowable mixtures of the invention. Isto be understood that these ranges are approximations.

TABLE 1 Broad Preferred Mixture Ingredients/Properties¹ Range RangeNon-gelatin protein content 5-25% 9-15% % of non-gelatin proteinprovided by 50-100% 75-100% dairy protein Dairy protein 5-25% 9-15%Gelatin content 3-10% 5.2-8%   Gelatin Bloom value 150-350  200-300 Water content 35-70%  45-65%  Fat content 5-30% 12-25%  Emulsifyingsalts solids content 1-4%  1.2-2.5%  Whey powder content 0-10% 4-8% NFDM content 0-8%  0.5-4%   Dairy product² content 10-80%  15-50%  pH4.4-6.2  4.8-6.0  Temperature  150-190° F.  160-180° F. ¹All percentageson a weight basis, with the total weight of the mixture taken as 100% byweight. ²Dairy product is selected from the group consisting of cheese,yogurt, pudding and mixtures thereof.

The final product 28 resulting from the process is in the form of aresilient, self-sustaining body having a desirable mouth feel and“bite.” The product moreover has a refrigerated shelf life (40° F.) ofat least about six months, and a room temperature shelf life of at leastabout thirty days. The product is essentially free of visuallyobservable gelatin particles under a 25X magnification.

The following table sets forth important broad and preferred ingredientand property ranges for the final products of the invention. Again,these ranges are approximate.

TABLE 2 Broad Preferred Final Product Ingredients/Properties¹ RangeRange Non-gelatin protein content 6-36% 10.5-18%   % of non-gelatinprotein provided by 50-100% 75-100% dairy protein Dairy protein 6-36%10.5-18%   Gelatin content 4.5-12%   6.2-10.5% Gelatin Bloom value150-350  200-300  Water content 30-60%  35-50%  Fat content 6-36%14-30%  Emulsifying salts solids content 1.2-4.8%  1.4-3.0%  Whey powdercontent 0-12% 4-10% NFDM content 0-10% 0.6-5%   Dairy product² content12-90%  18-60%  pH 4.4-6.2  4.8-6.0  Water activity 0.7-1.0  0.8-0.9 Mass/surface area ratio 0.05-5    0.15-2    g/cm² g/cm² ¹All percentageson a weight basis, with the total weight of the mixture taken as 100% byweight. ²Dairy product is selected from the group consisting of cheese,yogurt, pudding and mixtures thereof.

The following examples set forth preferred formulae and procedures forproducing products in accordance with the invention. It is to beunderstood, however, that these examples are provided by way ofillustration and nothing therein should be taken as a limitation uponthe overall scope of the invention.

Example 1

In this example, a cheese snack product was prepared using the overallprocedure schematically illustrated in FIGS. 1-8, except that each ofthe starch depressions 20 were manually filled with cheese mixture.

The formula used for the flowable cheese mixture is set forth below.

TABLE 3 Ingredient % By Weight Water 29.52 Water from steam injection6.40 Cheddar cheese 43.89 NFDM 0.99 Whey powder 5.87 Carotenal 73 0.05Salt 0.56 Cream (80% fat) 4.11 Disodium phosphate 2.05 Lactic acid (50%)0.55 Sorbic acid 0.15 Gelatin (270 Bloom) 5.82

This mixture contained 43.89% cheese, 18.40% fat, 54.0% moisture, 6.08%carbohydrate, 0.15% sorbic acid, 4.62% ash, 0.89% whey protein, 16.9%other protein, 11.10% casein, 5.65% lactose, 1.62% emulsified solids,1.48% salt, 0.37% calcium, 1.09% sodium and 27.69% ash, carbohydratesand protein.

The ingredients of the mixture were placed in an auger-type lay downcooker and blended. During this time, culinary steam was injected intothe mixture for a period of about 1 minute, until the mixture reached atemperature of about 180° F. The steam injection was then terminated andmixing was continued for about 20 seconds. At this point, the mixturewas passed through a Votator shear pump to assure essential homogeneity.

A series of starch trays were prepared as described previously using lowmoisture (about 5-8%) particulate starch at 70-80° F. with a density ofabout 0.6 g/cm². A male mold plate having a series of shaped projections(e.g., different types of sports balls such as soccer and footballs) wasused to print the starch layer and form appropriately configureddepressions therein. The prepared, heated cheese mixture was thenmanually deposited in each depression to fill it. The filled trays werethen allowed to stand at room temperature for a period of about twohours. The contents of the trays were then dumped into a sieve apparatusto separate the majority of the starch from the hardened food productbodies. As a final measure, these bodies were passed under a positivepressure air stream to remove all residual starch.

The final snack product had the following profile: moisture, 56.0%, fat,22.40%, carbohydrate, 7.40%, sorbic acid, 0.19%, ash, 5.63%, wheyprotein, 1.08%, gelatin protein, 6.13%, casein, 13.52%, lactose, 6.88%,emulsifing solids, 1.97%, salt, 1.80%, calcium, 0.45%, and sodium,1.33%.

The final product had a pH of about 5.7 and exhibited desirableresilience and mouth feel qualities.

Example 2

In this example, a yogurt-based snack product was prepared. The startingformula was:

TABLE 4 Ingredient % By Weight Water 24.11 Water from steam injection6.40 Non-fat dry yogurt powder 12.98 FD&D Red 40 0.0014 Artificialstrawberry flavor 0.20 Natural strawberry flavor 0.40 Strawberry puree7.50 Baker's sugar 15.0 Salt 0.50 Cream (80% fat) 25.38 Sorbic acid 0.20Gelatin (270 Bloom) 7.30

This mixture had the following profile: fat, 16.99%, moisture, 55.40%,carbohydrate, 18.19%, sorbic acid, 0.16%, ash, 1.36%, whey protein,0.77%, protein, 9.06%, casein, 3.27%, gelatin protein, 6.31%, lactose,5.58%, salt, 0.56%, calcium, 0.13%, sodium, and 0.24%, ash.

The foregoing ingredients were prepared as described in Example 1 anddeposited into preformed starch bed openings, and allowed to hardentherein. Separation of starch and recovery of the hardened finalproducts was likewise carried out as in Example 1. The final product hadthe following profile: fat, 20.68%, moisture, 44.00%, carbohydrate,22.15%, sorbic acid, 0.20%, ash, 1.66%, whey protein, 0.94%, protein,11.03%, casein, 3.98%, gelatin protein, 6.31%, lactose, 6.80%, salt,0.68%, calcium, 0.15%, and sodium, 0.29%. This product had a pH of about5.1.

We claim:
 1. A method of forming a resilient, self-sustaining foodproduct body comprising the steps of: providing a layer of particulatestarch presenting an upper surface; forming a depression in said starchlayer through said upper surface, said depression having a desiredcontour below said upper surface; filling said depression with aflowable mixture including non-gelatin protein, gelatin, water and fat,the non-gelatin protein content of the mixture comprising a quantity ofdairy product-derived protein; allowing said mixture to harden withinsaid depression to form said self-sustaining body, said body presentinga surface complemental with said depression contour; and separating saidbody from said starch.
 2. The method of claim 1, including the step oftreating said starch so that the starch has a total water content offrom about 5-8% by weight prior to said forming step.
 3. The method ofclaim 1, including the step of treating said starch so that the starchis at a temperature of from about 70-100° F. during said hardening step.4. The method of claim 1, said mixture having a temperature of fromabout 150-190° F. during said filling step.
 5. The method of claim 1,said starch having a density of from about 0.5-0.7 g/cm².
 6. The methodof claim 1, said mixture being prepared by blending the ingredientsthereof and injecting steam into the ingredients during said blending,followed by subjecting the steam-injected mixture to high shearprocessing to render the mixture essentially homogeneous.
 7. The methodof claim 1, including the step of allowing said mixture to harden at atemperature of from about 30-90° F.
 8. The method of claim 1, includingthe step of allowing said mixture to harden for a period of from about45 minutes to 4 hours.
 9. The method of claim 1, including the step ofallowing the mixture to harden until the self-sustaining body has amoisture content of from about 30-60% by weight, and a temperature offrom about 40-90° F.
 10. The method of claim 1, said separating stepcomprising the steps of first sifting starch from said self-sustainingbody, followed by air removal of residual starch therefrom.
 11. Themethod of claim 1, including the step of cooling said separated body toa temperature of from about 35-50° F.
 12. The method of claim 11,including the step of packaging the cooled body in a reduced oxygenpackage.
 13. The method of claim 1, said gelatin having a gel strengthof from about 150-350 Bloom.
 14. The method of claim 13, said gelstrength being from about 200-300 Bloom.
 15. The method of claim 1, saidmixture including a quantity of emulsifying salts solids content. 16.The method of claim 1, said mixture having a non-gelatin protein contentof from about 5-25%.
 17. The method of claim 1, from about 50-100% ofsaid non-gelatin protein content being made up of said dairyproduct-derived protein.
 18. The method of claim 1, said mixture havinga gelatin content of from about 3-10% by weight.
 19. The method of claim1, said mixture having a water content of from about 35-70% by weight.20. The method of claim 1, said mixture having a fat content of fromabout 5-30% by weight.
 21. The method of claim 1, said body having awater activity of from about 0.7-1.0.
 22. The method of claim 1, saidbody having a mass to surface area ratio of from about 0.05-5 g/cm². 23.The method of claim 1, said body having a pH of from about 4.4-6.2. 24.The method of claim 1, said mixture including therein an ingredientselected from the group consisting of cheese, yogurt, pudding andmixtures thereof.
 25. The method of claim 24, said cheese being selectedfrom the group consisting of cream cheese, American, Cheddar, Colby,Monterey jack, Swiss, mozzarella and mixtures thereof.
 26. The method ofclaim 24, said ingredient being present in said mixture at a level offrom about 10-80%.
 27. The method of claim 1, said mixture includingrespective quantities of one or more ingredients selected from the groupconsisting of whey, powder, non-fat dry milk powder, lactic acid,preservatives and colors.
 28. The method of claim 1, said body beingessentially free of visually observable gelatin particles under a 25Xmagnification.